Catalyst for Epoxidation of Propylene

Abstract

The present invention relates to a catalyst molded body comprising a zeolite material having a skeletal MFI, wherein the catalyst molded body has a specific average compressive strength and a specific aspect ratio. Furthermore, the present invention relates to a reactor comprising a plurality of the catalyst molded bodies. Furthermore, the present invention relates to a method for producing the catalyst molded body, and a catalyst molded body that can be obtained or obtained by the method. Furthermore, the present invention relates to a method for activating hydrogen peroxide, and a method for using the catalyst molded body as a catalyst and / or catalytic component, or the reactor in a reaction involving one or more of CO bond formation, CC bond formation, and / or CC bond conversion. Furthermore, the present invention relates to a method for producing olefin oxides.

Claims

1. A catalyst molded article comprising a zeolite material having a skeletal MFI, The catalyst molded body has an average compressive strength in the range of 3 to 30 N. The catalyst molded body has an aspect ratio D1:D2, A catalyst molded body in which D1 represents the maximum distance that separates a pair of parallel planes P1 and P2 when the catalyst molded body is located between parallel planes P1 and P2, without crossing them, and the catalyst molded body is in contact with each plane at at least one point, and D2 represents the shortest distance that separates a pair of parallel planes P3 and P4 when the catalyst molded body is located between parallel planes P3 and P4, without crossing them, and the catalyst molded body is in contact with each plane at at least one point, and the aspect ratio D1:D2 is 1:1 or greater.

2. The catalyst molded article according to claim 1, wherein D1 is in the range of 0.1 to 10 mm and / or D2 is in the range of 0.05 to 5 mm.

3. A catalyst molded body according to claim 1 or 2, having a total pore volume in the range of 0.60 to 1.2 ml / g.

4. A catalyst molded article according to any one of claims 1 to 3, exhibiting a water adsorption amount in the range of 1.0 to 15.0% by mass.

5. A catalyst molded article according to any one of claims 1 to 4, having a Ti content in the range of 0.4 to 1.85 mass%, calculated as elemental Ti based on the total mass of the zeolite material and any one or more oxide binders.

6. Water adsorption amount (W), quantitative determination １７ O is determined by NMR spectroscopy, H ２ O ２ Crosslinking μ per unit of Ti in activated catalyst molded article ２ η ２ - The concentration of the peroxo species (C) and the activator (A) according to formula I are shown, wherein the activator is in the range of 10 to 75 mmol / mol; A = W × C (I) According to Formula I, the activating factor is the water adsorption amount and H ２ O ２ the crosslinked μ ２ η ２ - the concentration of peroxo species per Ti in the activated catalyst molded body, the catalyst molded body according to any one of claims 1 to 5.

7. 200-450m ２ A catalyst molded article according to any one of claims 1 to 6, having a BET specific surface area in the range of / g.

8. A catalyst molded article according to any one of claims 1 to 7, exhibiting selectivity for the sum of 1-methoxy-2-propanol and 2-methoxy-1-propanol in the range of 0 to 15%.

9. A catalyst molded body according to any one of claims 1 to 8, wherein it exhibits a deactivation rate in the range of 0 to 0.055 K / h, preferably in the range of 0.001 to 0.035 K / h, and the deactivation rate is determined by the method described in Example 14.

10. A catalyst molded article according to any one of claims 1 to 9, having a bulk density of 320 g / l or more.

11. A reactor comprising a plurality of catalyst molded bodies, wherein each of the catalyst molded bodies is independently a catalyst molded body according to any one of claims 1 to 10, and 42% to 100% of the plurality of catalyst molded bodies have an aspect ratio in the range of greater than 1.5 to less than 6.

1.

12. A method for preparing a catalyst molded article according to any one of claims 1 to 11, comprising the following steps: (i) a step of preparing a mixture comprising one or more binder precursors and a zeolite material having a skeletal MFI; (ii) A step of forming the mixture obtained from step (i) into a catalyst molded body precursor to obtain a catalyst molded body precursor; (iii) Optionally, a step of preparing a mixture containing the catalyst molded body precursor obtained from step (ii) and water, subjecting the mixture to hydrothermal treatment to obtain a water-treated catalyst molded body precursor; (iv) A step of obtaining a catalyst molded body by calcining the catalyst molded body precursor obtained from step (ii) or the water-treated catalyst molded body precursor obtained from step (iii) in a gas atmosphere. Methods that include...

13. A method for activating hydrogen peroxide, (1) A step of providing a reactor comprising a catalyst molded body according to any one of claims 1 to 10, or the reactor according to claim 10; and (2) A step of bringing the catalyst molded body provided in step (1), or a plurality of catalyst molded bodies contained in the reactor provided in step (1), into contact with hydrogen peroxide. Methods that include...

14. A method for using a catalyst molded body according to any one of claims 1 to 10 as a catalyst and / or catalyst component, or a reactor according to claim 11, in a reaction involving one or more of C-O bond formation, C-C bond formation, and C-C bond conversion.

15. A method for preparing olefin oxides, (A) Providing an olefin, hydrogen peroxide, water, an organic solvent, and optionally an additive to an epoxidation zone containing a catalyst molded body according to any one of claims 1 to 10, or a reactor according to claim 11, as a catalyst and / or catalytic component, to obtain a reaction mixture containing an olefin, hydrogen peroxide, water, and an organic solvent; (B) The reaction mixture obtained from step (A) is subjected to epoxidation reaction conditions in the epoxidation zone to obtain a mixture containing olefin oxide, water and an organic solvent; (C) A step of removing the discharge stream containing olefin oxide, water and organic solvent from the epoxidation zone. Methods that include...

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